Polycarbonate composition to produce optical quality products with high quality and good processability

ABSTRACT

A process for manufacturing a polycarbonate composition includes melt polymerizing a dihydroxy compound and a carbonate compound in the presence of a catalyst to form a polycarbonate; and adding 1 to 400 ppm of glycerol tristearate to form the polycarbonate composition, wherein the polycarbonate composition is unquenched.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of European Patent ApplicationSerial No. 13382236.1 filed Jun. 21, 2013 and is a continuationapplication of U.S. application Ser. No. 14/307,793 filed on Jun. 18,2014. The related applications are incorporated herein by reference intheir entirety.

TECHNICAL FIELD

This disclosure generally relates to the production of unquenched meltpolycarbonate.

BACKGROUND

Melt polymerization of polycarbonate is typically achieved by reacting abisphenol compound with a carbonate compound in a series of reactors inthe presence of a catalyst. After the polymerization is complete, thecatalyst is generally quenched (referred to herein as a quenchedpolycarbonate), and any additives are added to result in a polycarbonatecomposition. Polycarbonate compositions for media storage applications(such as CD, DVD, and BLU-RAY™ discs) produced by melt polycondensationprocesses typically experience quality issues, such as a reduction inthe optical properties, when the catalyst is not quenched (referred toherein as an unquenched polycarbonate). This reduction in opticalquality can ultimately reduce the applicability of unquenchedpolycarbonate for media storage applications.

The reduction in the optical properties in unquenched polycarbonate canoccur due to the presence of active polymerization catalyst, which cancatalyze the reactions between certain additives and the polycarbonatebackbone. For example, mold release agents are typically added toquenched polycarbonate compositions to facilitate further processing ofthe resultant polycarbonate composition. In quenched polycarbonate,glycerol monostearate (GMS) and/or pentaerythritol tristearate (PETS)are typically added as the mold release agent. However, GMS moleculescontain hydroxyl groups that can react with polycarbonate in thepresence of an active catalyst, which results in a reduction in theoptical properties such that the composition is not suitable for use asin media storage applications. PETS has been shown to have goodstability in unquenched polycarbonate, but has also been shown to reducethe optical quality of discs molded therefrom.

An unquenched, melt polycarbonate composition comprising a mold releaseagent that could be used for media storage applications and a process ofmaking the same is therefore desirable.

SUMMARY

Disclosed herein are methods for making melt polycarbonate compositionsand systems for making melt polycarbonate compositions, and thepolycarbonate composition made therefrom.

In an embodiment, a process for manufacturing a polycarbonatecomposition can comprise: melt polymerizing a dihydroxy compound and acarbonate compound in the presence of a catalyst to form apolycarbonate; and adding 1 to 400 ppm of glycerol tristearate to formthe polycarbonate composition, wherein the polycarbonate composition isunquenched, wherein the polycarbonate has a weight average molecularweight of 8,000 to 19,000 Daltons as determined by gel permeationchromatography and based on polycarbonate standards.

The above described and other features are exemplified by the followingfigures and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings wherein likeelements are numbered alike and which are presented for the purposes ofillustrating the exemplary embodiments disclosed herein and not for thepurposes of limiting the same.

FIG. 1 schematically depicts a plant design for the production ofpolycarbonate where a catalyst quenching agent is not added; and

FIG. 2 is a graphical illustration of the resultant cloud level ofExamples 1-11.

DETAILED DESCRIPTION

Several melt polycarbonate (PC) processes stabilize polycarbonate byquenching, that is, neutralizing residual active polymerization catalystwith a quenching agent. Quenching agents are typically acidic and differfrom additives added for other purposes that may decrease catalystactivity. As is understood in the art, a “quenching agent” decreases theactivity of the catalyst to prevent unwanted reactions from occurringduring the final stages of manufacture, for example, when variousadditives are added to the polycarbonate composition. The quenchingagent can minimize or prevent reactions that can occur between anadditive and the polymer backbone in the presence of the activecatalyst. Such reactions can result in one or more of a loss ofefficiency of the additive, a change in the molecular weight of thepolycarbonate, and a change in a property of the resultant polycarbonatecomposition (such as a reduction in the optical properties). It wassurprisingly found that 1 to 400 parts per million by weight (ppm),specifically, 50 to 350 ppm, more specifically, 100 to 200 ppm of themold release agent glycerol tristearate (GTS) can be added to anunquenched melt polycarbonate to result in an optical grade meltpolycarbonate that can be used, for example, for media storageapplications. This result is particularly surprising because thelifetime of the alpha catalysts often used in the melt manufacture ofpolycarbonates is high, and virtually the entirety of the catalystsurvives the polymerization process.

As used herein, the term “unquenched polycarbonate” can include one ormore of a: (1) polycarbonate composition that comprises an activecatalyst; (2) a polycarbonate composition where the catalyst has notbeen neutralized, specifically, fully neutralized; (3) a polycarbonatecomposition where the reactivity between the polycarbonate and thecatalyst has not been reduced; (4) a polycarbonate composition whereinthe polycarbonate composition is formed without reducing the catalystactivity between the polymerization unit and the exit of the extruder bythe addition of a quenching agent; (5) a polycarbonate compositionwherein less than or equal to 50 mole percent (mol %) of an acidrelative to any added alpha catalyst has been added; and (6) apolycarbonate composition where substantially no quenching agent, asthat term is understood in the art, specifically Lewis or Bronstedacidic compound, has been added during the manufacture of thepolycarbonate.

In a specific embodiment, the term “unquenched polycarbonate” is apolycarbonate composition where substantially no quenching agent hasbeen added during the manufacture of the polycarbonate. As stated above,a “quenching agent” is a term of art that refers to an agent added to amelt polymerized polycarbonate specifically to reduce the level ofactivity of the catalyst. “Quenching agents” do not include componentscommonly used in the manufacture of polycarbonate compositions for onepurpose (e.g., as a heat stabilizer, ultraviolet light stabilizer, flameretardant, mold release agent, plasticizer, lubricant, dye, pigment, orthe like) that may also have the ancillary effect of reducing catalystactivity. Thus, in a specific embodiment, the term “unquenchedpolycarbonate” means a polycarbonate that does not include a substantialamount of a quenching agent, for example, 0 parts per million by weight(ppm) to less than 1 ppm, 0 ppm to less than 0.1 ppm, 0 ppm to less than0.01 ppm, or 0 ppm to less than 0.001 ppm, each based on the weight ofthe unquenched polycarbonate. In an embodiment, no quenching agent isadded.

Quenching agents include boric acid esters (e.g., B(OCH₃)₃, B(OCH₂CH₃)₃,and B(OC₆H₆)₃, zinc borate, boron phosphate, aluminum stearate, aluminumsilicate, zirconium carbonate, zirconium C₁-C₁₂ alkoxides, zirconiumhydroxycarboxylates, gallium phosphide, gallium antimonide, germaniumoxide, C₁-C₃₂ organogermanium compounds, C₄-C₃₂ tetraorganotin tincompound, C₆-C₃₂ hexaorganotin compound (e.g.,[(C₆H₆O)Sn(CH₂CH₂CH₂CH₃)₂]₂O), Sb₂O₃, antimony oxide, C₁-C₃₂alkylantimony, bismuth oxide, C₁-C₁₂ alkylbismuth, zinc acetate, zincstearate, C₁-C₃₂ alkoxytitanium, and titanium oxide, phosphoric acid,phosphorous acid, hypophosphorous acid, pymphosphoric acid,polyphosphoric acid, boric acid, hydrochloric acid, hydrobromic acid,sulfuric acid, sulfurous acid, adipic acid, azelaic acid, dodecanoicacid, L-ascorbic acid, aspartic acid, benzoic acid, formic acid, aceticacid, citric acid, glutamic acid, salicylic acid, nicotinic acid,fumaric acid, maleic acid, oxalic acid, benzenesulfinic acid, C₁-C₁₂dialkyl sulfates (e.g., dimethyl sulfate and dibutyl sulfate), alkylsulfonic esters of the formula R₁SO₃R₂ wherein R₁ is hydrogen, C₁-C₁₂alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, and R₂ is C₁-C₁₂ alkyl, C₆-C₁₈aryl, or C₇-C₁₉ alkylaryl (e.g., benzenesulfonate, p-toluenesulfonate,methylbenzene sulfonate, ethylbenzene sulfonate, n-butylbenzenesulfonate, octyl benzenesulfonate and phenyl benzenesulfonate,methyl p-toluenesulfonate, ethyl p-toluenesulfonate, n-butyl p-toluenesulfonate, octyl p-toluenesulfonate and phenyl p-toluenesulfonate, inparticular alkyl tosylates such as n-butyl tosylate), sulfonic acidphosphonium salts of the formula (R^(a)SO₃ ⁻)(PR^(b) ₄)⁺ wherein R^(a)is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, and eachR^(b) is independently hydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl, sulfonicacid derivatives of the formula A¹-(Y¹—SO₃X¹)_(m) wherein A¹ is a C₁-C₄₀hydrocarbon group having a valence of m, Y¹ is a single bond or anoxygen atom, X¹ is a secondary or tertiary alkyl group of the formula—CR¹⁵R¹⁶R¹⁷, a metal cation of one equivalent, an ammonium cation (e.g.,NR^(b) ₃ ⁺ wherein each R^(b) is independently hydrogen, C₁-C₁₂ alkyl orC₆-C₁₈ aryl), or a phosphonium (e.g., PR^(b) ₄ ⁺ wherein each R^(b) isindependently hydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl) wherein R¹⁵ is ahydrogen atom or an alkyl group having 1 to 5 carbon atoms, R¹⁶ is ahydrogen atom, a phenyl group or an alkyl group having 1 to 5 carbonatoms, and R¹⁷ is the same as or different from R¹⁵ and has the samedefinition as R¹⁵, provided that two of R¹⁵. R¹⁶, and R¹⁷ cannot behydrogen atoms, and m is an integer of 1 to 4, provided that when Y¹ isa single bond, all of X¹ in an amount of m cannot be metal cations ofone equivalent, a compound of the formula ⁺X²-A²-Y¹—SO₃ ⁻ wherein A² isa divalent hydrocarbon group, ⁺X² is a secondary, tertiary or quaternaryammonium cation or a secondary (e.g., tertiary or quaternary phosphoniumcation, and Y¹ is a single bond or an oxygen atom, a compound of theformula A³-(⁺X³)_(n)—(R—Y¹—SO₃ ⁻)_(n) wherein A³ is a C₁-C₄₀ hydrocarbongroup having a valence of n, ⁺X³ is a secondary, tertiary or quaternaryammonium cation (e.g., NR^(b) ₃ ⁺ wherein each R^(b) is independentlyhydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl), or a secondary, tertiary orquaternary phosphonium cation (e.g., PR^(b) ₄ ⁺ wherein each R^(b) isindependently hydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl), R is a monovalentC₁-C₄₀ hydrocarbon group, n is an integer of 2 to 4, and Y¹ is a singlebond or an oxygen atom, a compound of the formula A⁵-Ad¹-A⁴-(Ad²-A⁵)_(l)wherein A⁵ is a monovalent or divalent C₁-C₄₀ hydrocarbon group, A⁴ is adivalent C₁-C₄₀ hydrocarbon group, each of Ad¹ and Ad² is independentlyan acid anhydride group selected from —SO₂—O—SO₂—, —SO₂—O—CO— and—CO—O—SO₂—, and l is 0 or 1, provided that when l is O, -(Ad²-A⁵)_(l) isa hydrogen atom or a bond between A⁴ and A⁵, in which A⁵ is a divalenthydrocarbon group or a single bond, aminosulfonic esters having theformula R_(a)R_(b)N-A-SO₃R_(c), wherein R_(a) and R_(b) are eachindependently hydrogen, C₁-C₁₂ alkyl, C₆-C₂₂ aryl, C₇-C₁₉ alkylaryl orR_(a) and R_(b), either singly or in combination, form an aromatic ornon-aromatic heterocyclic compound with N (e.g., pyrrolyl, pyridinyl,pyrimidyl, pyrazinyl, carbazolyl, quinolinyl, imidazoyl, piperazinyl,oxazolyl, thiazolyl, pyrazolyl, pyrrolinyl, indolyl, purinyl,pyrrolidinyl, or the like), R, is hydrogen, and A is C₁-C₁₂ alkyl,C₆-C₁₈ aryl, or C₁₇-C₁₉ alkylaryl (e.g., compounds such asN-(2-hydroxyethyl) piperazine-N′-3-propanesulfonic acid,1,4,-piperazinebis (ethanesulfonic acid), and5-dimethylamino-1-napthalenesulfonic acid), ammonium sulfonic esters ofthe formula R_(a)R_(b)R_(c)N⁺-A-SO₃ ⁻, wherein R_(a), R_(b), are eachindependently hydrogen, C₁-C₁₂ alkyl, C₁-C₁₂ aryl, C₇-C₁₉ alkylaryl, orR_(a) and R_(b), either singly or in combination, form an aromatic ornon-aromatic heterocyclic compound with N (e.g., pyrrolyl, pyridinyl,pyrimidyl, pyrazinyl, carbazolyl, quinolinyl, imidazoyl, piperazinyl,oxazolyl, thiazolyl, pyrazolyl, pyrrolinyl, indolyl, purinyl,pyrrolydinyl, or the like), R_(c) is a hydrogen, and A is C₁-C₁₂ alkyl,C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, sulfonated polystyrene, methylacrylate-sulfonated styrene copolymer, and combinations comprising atleast one of the foregoing. Quenching agents can include a combinationof compounds, for example, an alkyl tosylate such as n-butyl tosylateand phosphorus acid.

A “polycarbonate” as used herein means compositions having repeatingstructural carbonate units of formula (1)

in which at least 60 percent of the total number of R¹ groups containaromatic moieties and the balance thereof are aliphatic, alicyclic, oraromatic. Each R¹ can be a C₆₋₃₀ aromatic group, that is, contains atleast one aromatic moiety. R¹ can be derived from a dihydroxy compoundof the formula HO—R¹—OH, in particular of formula (2)HO-A¹-Y¹-A²-OH  (2)wherein each of A¹ and A² is a monocyclic divalent aromatic group and Y¹is a single bond or a bridging group having one or more atoms thatseparate A¹ from A². One atom can separate A¹ from A². Specifically,each R¹ can be derived from a bisphenol of formula (3)

wherein R^(a) and R^(b) are each independently a halogen, C₁₋₁₂ alkoxy,or C₁₋₁₂ alkyl; and p and q are each independently integers of 0 to 4.It will be understood that R^(a) is hydrogen when p is 0, and likewiseR^(b) is hydrogen when q is 0. Also in formula (3), X^(a) is a bridginggroup connecting the two hydroxy-substituted aromatic groups, where thebridging group and the hydroxy substituent of each C₆ arylene group aredisposed ortho, meta, or para (specifically, para) to each other on theC₆ arylene group. The bridging group X^(a) can be single bond, —O—, —S—,—S(O)—, —S(O)₂—, —C(O)—, or a C₁₋₁₈ organic group. The C₁₋₁₈ organicbridging group can be cyclic or acyclic, aromatic or non-aromatic, andcan further comprise heteroatoms such as halogens, oxygen, nitrogen,sulfur, silicon, or phosphorous. The C₁₋₁₈ organic group can be disposedsuch that the C₆ arylene groups connected thereto are each connected toa common alkylidene carbon or to different carbons of the C₁₋₁₈ organicbridging group. p and q can each be 1, and R^(a) and R^(b) are each aC₁₋₃ alkyl group, specifically, methyl, disposed meta to the hydroxygroup on each arylene group.

X^(a) can be a substituted or unsubstituted C₃₋₁₈ cycloalkylidene, aC₁₋₂₅ alkylidene of formula —C(R^(c))(R^(d))— wherein R^(c) and R^(d)are each independently hydrogen, C₁₋₁₂ alkyl, C₁₋₁₂ cycloalkyl, C₇₋₁₂arylalkyl, C₁₋₁₂ heteroalkyl, or cyclic C₇₋₁₂ heteroarylalkyl, or agroup of the formula —C(═R^(c))— wherein R is a divalent C₁₋₁₂hydrocarbon group. Groups of this type include methylene,cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, aswell as 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, cyclopentylidene,cyclododecylidene, and adamantylidene.

X^(a) can be a C₁₋₁₈ alkylene group, a C₃₋₁₈ cycloalkylene group, afused C₆₋₁₈ cycloalkylene group, or a group of the formula —B¹-G-B²—wherein B¹ and B² are the same or different C₁₋₆ alkylene group and G isa C₃₋₁₂ cycloalkylidene group or a C₆₋₁₆ arylene group. For example,X^(a) can be a substituted C₃₋₁₈ cycloalkylidene of formula (4)

wherein R^(r), R^(p), R^(q), and R^(t) are each independently hydrogen,halogen, oxygen, or C₁₋₁₂ hydrocarbon groups; Q is a direct bond, acarbon, or a divalent oxygen, sulfur, or —N(Z)— where Z is hydrogen,halogen, hydroxy, C₁₋₁₂ alkyl, C₁₋₁₂ alkoxy, or C₁₋₁₂ acyl; r is 0 to 2,t is 1 or 2, q is 0 or 1, and k is 0 to 3, with the proviso that atleast two of R^(r), R^(p), R^(q), and R^(t) taken together are a fusedcycloaliphatic, aromatic, or heteroaromatic ring. It will be understoodthat where the fused ring is aromatic, the ring as shown in formula (4)will have an unsaturated carbon-carbon linkage where the ring is fused.When k is one and i is 0, the ring as shown in formula (4) contains 4carbon atoms, when k is 2, the ring as shown in formula (4) contains 5carbon atoms, and when k is 3, the ring contains 6 carbon atoms. Twoadjacent groups (e.g., R^(q) and R^(t) taken together) can form anaromatic group or R^(q) and R^(t) taken together can form one aromaticgroup and R^(r) and R^(p) taken together can form a second aromaticgroup. When R^(q) and R^(t) taken together form an aromatic group, R^(p)can be a double-bonded oxygen atom, i.e., a ketone.

Bisphenols (3) wherein X^(a) is a substituted C₃₋₁₈ cycloalkylidene offormula (4) can be used in the manufacture of polycarbonates containingphthalimidine carbonate units of formula (1a)

wherein R^(a), R^(b), p, and q are as in formula (3), R³ is eachindependently a C₁₋₆ alkyl group, j is 0 to 4, and R₄ is a C₁₋₆ alkyl,phenyl, or phenyl substituted with up to five C₁₋₆ alkyl groups. Thephthalimidine carbonate units can be of formula (1b)

wherein R⁵ is hydrogen or a C₁₋₆ alkyl. R⁵ can be hydrogen. Carbonateunits (1a) wherein R⁵ is hydrogen can be derived from2-phenyl-3,3′-bis(4-hydroxy phenyl)phthalimidine (also known as N-phenylphenolphthalein bisphenol, or “PPPBP”) (also known as3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one).

Other bisphenol carbonate repeating units of this type are the isatincarbonate units of formulas (1c) and (1d)

wherein R^(a) and R^(b) are each independently C₁₋₁₂ alkyl, p and q areeach independently 0 to 4, and R^(i) is C₁₋₁₂ alkyl, phenyl, optionallysubstituted with 1 5 to C₁₋₁₀ alkyl, or benzyl optionally substitutedwith 1 to 5 C₁₀ alkyl. R^(a) and R^(b) can each be methyl, p and q caneach independently be 0 or 1, and R^(i) can be C₁₋₄ alkyl or phenyl.

Examples of bisphenol carbonate units derived from bisphenols (3)wherein X^(a) is a substituted or unsubstituted C₃₋₁₈ cycloalkylidene(4) include the cyclohexylidene-bridged, alkyl-substituted bisphenol offormula (1e)

wherein R^(a) and R^(b) are each independently C₁₋₁₂ alkyl, R^(g) isC₁₋₁₂ alkyl, p and q are each independently 0 to 4, and t is 0 to 10. Atleast one of each of R^(a) and R^(b) can be disposed meta to thecyclohexylidene bridging group. R^(a) and R^(b) can each independentlybe C₁₋₄ alkyl, R^(g) can be C₁₋₄ alkyl, p and q can each be 0 or 1, andt is 0 to 5. R^(a), R^(b), and R^(g) can each be methyl, r and s caneach be 0 or 1, and t can be 0 or 3, specifically, 0.

Examples of other bisphenol carbonate units derived from bisphenol (3)wherein X^(a) is a substituted or unsubstituted C₃₋₁₈ cycloalkylideneinclude adamantyl units (1f) and units (1g)

wherein R^(a) and R^(b) are each independently C₁₋₁₂ alkyl, and p and qare each independently 1 to 4. At least one of each of R^(a) and R^(b)can be disposed meta to the cycloalkylidene bridging group. R^(a) andR^(b) can each independently be C₁₋₃ alkyl, and p and q can each be 0or 1. R^(a), R^(b) can each be methyl, p and q can each be 0 or 1.Carbonates containing units (1a) to (1g) are useful for makingpolycarbonates with high glass transition temperatures (Tg) and highheat distortion temperatures.

Other possible dihydroxy compounds of the formula HO—R¹—OH includecompounds of formula (5)

wherein each R^(h) is independently a halogen atom, a C₁₋₁₀ hydrocarbylsuch as a C₁₋₁₀ alkyl group, a halogen-substituted C₁₋₁₀ alkyl group, aC₆₋₁₀ aryl group, or a halogen-substituted C₆₋₁₀ aryl group, and n is 0to 4. The halogen can be bromine.

Some illustrative examples of specific aromatic dihydroxy compounds(herein also referred to as dihydroxy reactants) include the following:4,4′-dihydroxybiphenyl, 1,6-dihydroxynaphthalene,2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane,bis(4-hydroxyphenyl)diphenylmethane,bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane,1,1-bis(4-hydroxyphenyl)-1-phenylethane,2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane,bis(4-hydroxyphenyl)phenylmethane,2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane,1,1-bis(4-hydroxyphenyl)isobutene,1,1-bis(4-hydroxyphenyl)cyclododecane,trans-2,3-bis(4-hydroxyphenyl)-2-butene,2,2-bis(4-hydroxyphenyl)adamantane, alpha,alpha′-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile,2,2-bis(3-methyl-4-hydroxyphenyl)propane,2,2-bis(3-ethyl-4-hydroxyphenyl)propane,2,2-bis(3-n-propyl-4-hydroxyphenyl)propane,2,2-bis(3-isopropyl-4-hydroxyphenyl)propane,2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane,2,2-bis(3-t-butyl-4-hydroxyphenyl)propane,2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane,2,2-bis(3-allyl-4-hydroxyphenyl)propane,2,2-bis(3-methoxy-4-hydroxyphenyl)propane,2,2-bis(4-hydroxyphenyl)hexafluoropropane,1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene,1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene,1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene,4,4′-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone,1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycolbis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether,bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide,bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorine,2,7-dihydroxypyrene,6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindanebisphenol”), 3,3-bis(4-hydroxyphenyl)phthalimide,2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene,2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine,3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and2,7-dihydroxycarbazole, resorcinol, substituted resorcinol compoundssuch as 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol,5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenyl resorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluoro resorcinol, 2,4,5,6-tetrabromoresorcinol, or the like; catechol; hydroquinone; substitutedhydroquinones such as 2-methyl hydroquinone, 2-ethyl hydroquinone,2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone,2-phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromo hydroquinone, or the like, orcombinations comprising at least one of the foregoing dihydroxycompounds.

Specific examples of bisphenol compounds of formula (3) include1,1-bis(4-hydroxyphenyl) methane, 1,1-bis(4-hydroxyphenyl) ethane,2,2-bis(4-hydroxyphenyl) propane (hereinafter “bisphenol A” or “BPA”),2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane,1,1-bis(4-hydroxyphenyl) propane, 1,1-bis(4-hydroxyphenyl) n-butane,2,2-bis(4-hydroxy-2-methylphenyl) propane,1,1-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4-hydroxyphenyl)phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl) phthalimidine (PPPBP),and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). Combinationscomprising at least one of the foregoing dihydroxy compounds can also beused. The polycarbonate can be a linear homopolymer derived frombisphenol A, in which each of A¹ and A² can be p-phenylene, and Y¹ canbe isopropylidene in formula (3).

The diaryl carbonate can have the formula (I)

wherein n is an integer 1 to 3 and each R₂ is independently a linear orbranched, optionally substituted C₁₋₃₄ alkyl (specifically C₁₋₆ alkyl,more specifically C₁₋₄ alkyl), C₁₋₃₄ alkoxy (specifically C₁₋₆ alkoxy,more specifically C₁₋₄ alkoxy), C₅₋₃₄ cycloalkyl, C₇₋₃₄ alkylaryl C₆₋₃₄aryl, a halogen radical (specifically a chlorine radical), or —C(═O)OR′wherein R′ is H, linear or branched C₁₋₃₄ alkyl (specifically C₁₋₆alkyl, more specifically C₁₋₄ alkyl), C₁₋₃₄ alkoxy (specifically C₁₋₁₆alkoxy, specifically C₁₋₄ alkoxy), C₅₋₃₄ cycloalkyl, C₇₋₃₄ alkylaryl, orC₆₋₃₄ aryl.

The molar ratio of the diaryl carbonate to the dihydroxy compound can begreater than 1, equal to 1, or less than 1. The molar ratio of thediaryl carbonate to the dihydroxy compound can be less than 1 whenexpressed to at least three decimal places, for example, 0.996 or less,specifically, 0.962 to 0.996, more specifically, 0.968 to 0.996, evenmore specifically, 0.971 and 0.994. The diaryl carbonate to dihydroxycompound can be present in a molar ratio of 2:1 to 1:2, specifically, ina molar ratio of 1.5:1 to 1:1.5, more specifically, in a molar ratio of1.05:1 to 1:1.05, even more specifically, in a molar ratio of 1:1.

“Polycarbonates” as used herein further includes homopolycarbonates(wherein each R¹ in the polymer is the same), copolymers comprisingdifferent R¹ moieties in the carbonate (“copolycarbonates”), copolymerscomprising carbonate units and other types of polymer units, such asester units, and combinations comprising at least one ofhomopolycarbonates and/or copolycarbonates.

A specific type of copolymer is a polyester carbonate, also known as apolyester-polycarbonate. Such copolymers further contain, in addition torecurring carbonate chain units of formula (1), repeating units offormula (7)

wherein J is a divalent group derived from a dihydroxy compound, and canbe, for example, a C₂₋₁₀ alkylene, a C₆₋₂₀ cycloalkylene a C₆₋₂₀arylene, or a polyoxyalkylene group in which the alkylene groups contain2 to 6 carbon atoms, specifically, 2, 3, or 4 carbon atoms; and T is adivalent group derived from a dicarboxylic acid, and can be, forexample, a C₂₋₁₀ alkylene, a C₆₋₂₀ cycloalkylene, or a C₆₋₂₀ arylene.Copolyesters containing a combination of different T and/or J groups canbe used. The polyesters can be branched or linear.

J can be a C₂₋₃₀ alkylene group having a straight chain, branched chain,or cyclic (including polycyclic) structure. J can be derived from anaromatic dihydroxy compound of formula (3) above. J can be derived froman aromatic dihydroxy compound of formula (4) above. J can be derivedfrom an aromatic dihydroxy compound of formula (5) above.

Aromatic dicarboxylic acids that can be used to prepare the polyesterunits include isophthalic or terephthalic acid,1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether,4,4′-bisbenzoic acid, or a combination comprising at least one of theforegoing acids. Acids containing fused rings can also be present, suchas in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specificdicarboxylic acids include terephthalic acid, isophthalic acid,naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, or acombination comprising at least one of the foregoing acids. A specificdicarboxylic acid comprises a combination of isophthalic acid andterephthalic acid wherein the weight ratio of isophthalic acid toterephthalic acid is 91:9 to 2:98. J can be a C₂₋₆ alkylene group and Tcan be p-phenylene, m-phenylene, naphthalene, a divalent cycloaliphaticgroup, or a combination thereof. This class of polyester includes thepoly(alkylene terephthalates).

The molar ratio of ester units to carbonate units in the copolymers canvary broadly, for example 1:99 to 99:1, specifically, 10:90 to 90:10,more specifically, 25:75 to 75:25, depending on the desired propertiesof the final composition.

The polyester unit of a polyester-polycarbonate can be derived from thereaction of a combination of isophthalic and terephthalic diacids (orderivatives thereof) with resorcinol. The polyester unit of apolyester-polycarbonate can be derived from the reaction of acombination of isophthalic acid and terephthalic acid with bisphenol A.The polycarbonate units can be derived from bisphenol A. Thepolycarbonate units can be derived from resorcinol and bisphenol A in amolar ratio of resorcinol carbonate units to bisphenol A carbonate unitsof 1:99 to 99:1.

The polycarbonate can be made by a melt polymerization process, byco-reacting, in a molten state, monomers such as a dihydroxy reactantand a carbonate compound, such as phosgene or diphenyl carbonate. Themelt polymerization process can be a batch or a continuous melt process.In either case, the melt polymerization conditions used can comprise twoor more distinct reaction stages, for example, a first reaction stage inwhich the starting aromatic dihydroxy compound and diaryl carbonate areconverted into an oligomeric polycarbonate and a second reaction stagewherein the oligomeric polycarbonate formed in the first reaction stageis converted to high molecular weight polycarbonate. Such “staged”polymerization reaction conditions are especially suitable for use incontinuous polymerization systems wherein the starting monomers areoligomerized in a first reaction vessel and the oligomeric polycarbonateformed therein is continuously transferred to one or more downstreamreactors in which the oligomeric polycarbonate is converted to highmolecular weight polycarbonate. Typically, in the oligomerization stagethe oligomeric polycarbonate produced has a number average molecularweight (Mn) of 1,000 to 7,500 Daltons. In one or more subsequentpolymerization stages, the number average molecular weight of thepolycarbonate can be increased to 8,000 to 25,000 Daltons (usingpolycarbonate standard).

The polycarbonate can have a weight average molecular weight of 8,000 to19,000 Daltons, specifically, 13,000 to 18,500 Daltons, morespecifically, 13,000 to 18,000 Daltons as determined by gel permeationchromatography and based on polycarbonate standards.

The polycarbonate can have terminal hydroxyl groups in an amount of lessthan or equal to 20 mol %, specifically, less than or equal to 15 mol %,more specifically, less than or equal to 10 mol % based on the molartotal of all terminal groups of the polycarbonate.

The polycarbonate can have a melt flow of less than or equal to 40 gramsper 10 minutes (g/10 min), specifically, 4 to 40 g/10 min, specifically,4.5 to 15 g/10 min or 15 to 35 g/10 min as determined by ASTM D1238 at300 degrees Celsius (° C.), 1.5 kilograms (kg). The polycarbonate canhave a melt flow of less than or equal to 10 g/10 min as determined byASTM D1238 at 250° C., 1.5 kg.

The polycarbonate can have a light transparency of greater than 90% asdetermined using 3.2 mm thick samples using ASTM D1003-00, Procedure Busing CIE standard illuminant C, with unidirectional viewing.

The term “melt polymerization conditions” is understood to mean thoseconditions necessary to affect reaction between a dihydroxy compound anda carbonate compound in the presence of a transesterification catalyst.Although, solvents are generally not used in the process, and thereactants aromatic dihydroxy compound and the carbonate compound are ina molten state, the dihydroxy compound and/or the carbonate compound canbe added to the polymerization unit as a solvent mixture, such as amixture with acetone. The reaction temperature can be 100° C. to 350°C., specifically, 180° C. to 310° C. The pressure can be at atmosphericpressure, supra-atmospheric pressure, or a range of pressures fromatmospheric pressure to 15 torr in the initial stages of the reaction,and at a reduced pressure at later stages, for example, 0.2 to 15 torr.The reaction time is generally 0.1 hours to 10 hours.

A transesterification catalyst(s) can be employed in the polymerization.Such catalysts include phase transfer catalysts of formula (R³)₄Q⁺X,wherein each R³ is the same or different, and is a C₁₋₁₀ alkyl group; Qis a nitrogen or phosphorus atom; and X is a halogen atom or a C₁₋₈alkoxy group or C₆₋₁₈ aryloxy group. Transesterification catalystsinclude tetrabutylammonium hydroxide, methyltributylammonium hydroxide,tetrabutylammonium acetate, tetrabutylphosphonium hydroxide,tetrabutylphosphonium acetate, tetrabutylphosphonium phenolate, or acombination comprising at least one of the foregoing. The catalyst cancomprise a potassium sodium phosphate of the formula NaKHPO₄.

Catalysts used in the melt transesterification polymerization productionof polycarbonates can include alpha and/or beta catalysts. Betacatalysts are typically volatile and degrade at elevated temperaturesand can therefore be used at early low-temperature polymerizationstages.

Possible beta catalyst(s) can comprise a quaternary ammonium compound, aquaternary phosphonium compound, or a combination comprising at leastone of the foregoing. The quaternary ammonium compound can be a compoundof the structure (R⁴)₄N⁺X⁻, wherein each R⁴ is the same or different,and is a C₁₋₂₀ alkyl, a C₄₋₂₀ cycloalkyl, or a C₄₋₂₀ aryl; and X⁻ is anorganic or inorganic anion, for example, a hydroxide, halide, acetate,phenoxide, carboxylate, sulfonate, sulfate, formate, carbonate, orbicarbonate. Examples of organic quaternary ammonium compounds includetetramethyl ammonium hydroxide, tetrabutyl ammonium hydroxide,tetramethyl ammonium acetate, tetramethyl ammonium formate, tetrabutylammonium acetate, and combinations comprising at least one of theforegoing. Tetramethyl ammonium hydroxide is often used.

The quaternary phosphonium compound can be a compound of the structure(R⁵)₄P⁺X⁻, wherein each R⁵ is the same or different, and is a C₁₋₂₀alkyl, a C₄₋₂₀ cycloalkyl, or a C₄₋₂₀ aryl; and X⁻ is an organic orinorganic anion, for example, a hydroxide, halide, carboxylate,sulfonate, sulfate, formate, carbonate, or bicarbonate. Where X⁻ is apolyvalent anion such as carbonate or sulfate it is understood that thepositive and negative charges in the quaternary ammonium and phosphoniumstructures are properly balanced. For example, where R²⁰ to R²³ are eachmethyls and X⁻ is carbonate, it is understood that X⁻ represents 2 (CO₃⁻²). Examples of organic quaternary phosphonium compounds includetetramethyl phosphonium hydroxide, tetramethyl phosphonium acetate,tetramethyl phosphonium formate, tetrabutyl phosphonium hydroxide,tetrabutyl phosphonium acetate (TBPA), tetraphenyl phosphonium acetate,tetraphenyl phosphonium phenoxide, and combinations comprising at leastone of the foregoing. TBPA is often used.

The amount of beta catalyst employed is typically based upon the totalnumber of moles of dihydroxy compound employed in the polymerizationreaction. When referring to the ratio of beta catalyst, for example,phosphonium salt, to all dihydroxy compounds employed in thepolymerization reaction, it is convenient to refer to moles ofphosphonium salt per mole of the dihydroxy compound(s), meaning thenumber of moles of phosphonium salt divided by the sum of the moles ofeach individual dihydroxy compound present in the reaction mixture. Theamount of beta catalyst (e.g., organic ammonium or phosphonium salts)employed typically will be 1×10⁻² to 1×10⁻⁵, specifically, 1×10⁻³ to1×10⁻⁴ moles per total mole of the dihydroxy compounds in the reactionmixture.

Alpha catalysts are typically more thermally stable and less volatilethan beta catalysts. Nearly all of the alpha catalyst (e.g., greaterthan 80 weight percent (wt %), specifically greater than 90%) survivesthe polymerization process. As such, this catalyst is available tocatalyze additional (and generally unwanted) reactions downstream of thepolymerization process, such as in the extruder.

The alpha catalyst can comprise a source of alkali or alkaline earthions. The sources of these ions include alkaline earth hydroxides suchas magnesium hydroxide and calcium hydroxide. Sources of alkali metalions can include the alkali metal hydroxides such as illustrated bylithium hydroxide, sodium hydroxide, potassium hydroxide, andcombinations comprising at least one of the foregoing. Examples ofalkaline earth metal hydroxides are calcium hydroxide, magnesiumhydroxide, and combinations comprising at least one of the foregoing. Ofthese, sodium hydroxide is particularly desirable. The alpha catalysttypically will be used in an amount sufficient to provide 1×10⁻² to1×10⁻⁸ moles, specifically, 1×10⁻⁴ to 1×10⁻⁷ moles of metal hydroxideper mole of the dihydroxy compounds employed. Other possible sources ofalkaline earth and alkali metal ions include salts of carboxylic acids(such as sodium acetate) and derivatives of ethylene diamine tetraaceticacid (EDTA) (such as EDTA tetrasodium salt, and EDTA magnesium disodiumsalt), as well as combinations comprising at least one of the foregoing.For example, the alpha catalyst can comprise alkali metal salt(s) of acarboxylic acid, alkaline earth metal salt(s) of a carboxylic acid, or acombination comprising at least one of the foregoing. In anotherexample, the alpha catalyst comprises Na₂Mg EDTA or a salt thereof.

The alpha transesterification catalyst can also, or alternatively,comprise salt(s) of a non-volatile inorganic acid. For example, thealpha catalyst can comprise salt(s) of a non-volatile inorganic acidsuch as NaH₂PO₃, NaH₂PO₄, Na₂HPO₃, NaHCO₃, Na₂CO₃, KH₂PO₄, CsH₂PO₄,Cs₂HPO₄, Cs₂CO₃, and combinations comprising at least one of theforegoing. Alternatively, or in addition, the alpha transesterificationcatalyst can comprise mixed alkali metal salt(s) of phosphoric acid,such as NaKHPO₄, CsNaHPO₄, CsKHPO₄, and combinations comprising at leastone of the foregoing.

Branched polycarbonate can be prepared by adding a branching agentduring polymerization. These branching agents include polyfunctionalorganic compounds containing at least three functional groups selectedfrom hydroxyl, carboxyl, carboxylic anhydride, haloformyl, and mixturesof the foregoing functional groups. Specific examples includetrimellitic acid, trimellitic anhydride, trimellitic trichloride,tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC(1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA(4(4(1,1-bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethylbenzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, andbenzophenone tetracarboxylic acid. The branching agents can be added ata level of 0.05 to 2.0 wt %. Mixtures comprising linear polycarbonatesand branched polycarbonates can be used. The content of the followingbranching structures can be less than or equal to 2,000 ppm,specifically, less than or equal to 1,000 ppm, and more specifically,less than or equal to 500 ppm.

A branching agent can be employed in the polymerization and can resultin an increase in polymer melt strength. The branching agent(1,1,1-tris-(hydroxyphenyl) ethane (THPE)) can be introduced to thepolymerization unit, specifically, to a polymerization and/or anoligomerization vessel, as a solution of the branching agent dissolvedin a branching solvent. The branching solvent selected for dissolvingthe branching agent can be any solvent capable of dissolving thebranching agent at a level sufficient to deliver or introduce thedesired amount of branching agent into the polymerization unit. Thebranching solvent can comprise lower alkanols, such as C₁₋₄ alkanols,including methanol, ethanol, propanol (such as n-propanol andisopropanol), n-butanol, or a combination comprising one or more of theforegoing.

The branching agent can be introduced in an amount such that it willresult in a polycarbonate comprising up to 1.5 mol %, specifically, upto 1.0 mol %, more specifically, up to 0.5 mol % branching agent in thefinal branched polycarbonate. The amount of dissolved branching agentpresent in the solution can be an amount of 0.5 to 50 wt %,specifically, 5 to 40 wt %, more specifically, 15 to 35 wt % relative tothe total weight of the branching agent and solvent solution. Thepolymerized polycarbonate can comprise a branching agent in the amountof 100 to 5,000 ppm, specifically, 500 to 4,000 ppm, more specifically,1,000 to 3,500 ppm based on the total amount of polycarbonate repeatunits.

A chainstopper can be introduced to the polymerization unit. Thechainstopper can be, for example, a monofunctional phenol.

In general, melt polymerization of polycarbonate utilizes apolymerization unit that can comprise a mixer(s), a buffer vessel(s), anoligomerization vessel(s), a polymerization vessel(s), an extruder(s), ascrubber(s), a filter(s), or combinations comprising one or more of theforegoing. The melt polymerization unit can comprise a polymerizationvessel, a melt filter, and an extruder, wherein the melt filter islocated upstream from the extruder. The melt polymerization unit cancomprise a first and a second parallel line, wherein the first parallelline is connected to the melt filter located upstream from the extruder,and wherein the second parallel line is connected to a second meltfilter that is located upstream from a second extruder.

The polymerization can occur in a polymerization vessel or in a seriesof polymerization vessels that can have increasing temperature andvacuum. The initial polymerization vessels can be oligomerization units.

FIG. 1 illustrates a melt polycarbonate polymerization system.Initially, dihydroxy compound A and carbonate compound B can be added ata fixed molar ratio along with catalyst C, which can comprise a betacatalyst, to a pre-mixer 10 to form a pre-mixture. Likewise, thedihydroxy compound A and carbonate compound B can be combined to form amixture prior to addition to the pre-mixer 10.

The pre-mixer can be maintained at 160 to 180° C. and atmosphericpressure. The pre-mixture and any additional carbonate compound B andcatalyst C, where the additional carbonate compound B and/or catalyst Care the same or different as that added to the pre-mixer, can be sent toa first oligomerization vessel 20. The catalyst C can comprise an alphacatalyst. The first oligomerization vessel can operate at a temperatureof 230 to 260° C. and a vacuum of 140 to 200 millibar atmosphere (mbara)and phenol byproduct from polymerization reaction can be removed. Themixture can then flow into a second oligomerization vessel 21 that canoperate at a higher temperature of 270 to 290° C. and a deeper vacuum of30 to 50 mbara, e.g., for further phenol removal. The prepolymer, asformed in the oligomerization vessel, then flows to a firstpolymerization vessel 30 that can operate at a temperature of 290 to315° C. and 1 to 2.5 mbara. The effluent from the first polymerizationvessel can then flow to a second polymerization vessel 31 that canoperate at 290 to 315° C. and 0.5 to 1.5 mbara to result in theformation of a molten polycarbonate. Phenol by-product E and any solventcan be removed, for example, by a scrubber 50, from the oligomerizationvessel 20, 21 and/or from the polymerization vessel 30, 31.

The polymer can then flow to an extruder 40 where an additive F, forexample, a mold release agent (such as GTS) can be added to the moltenpolymer. The extruder 40 can be a twin-screw extruder and at least oneof the components can be incorporated by feeding directly into theextruder 40 at the throat and/or downstream through, for example, asidestuffer. Additives can also be compounded into a masterbatch withthe polymer and fed into the extruder. The extruder 40 can be operatedat a temperature that allows the composition to flow. After the extruder40, the resulting product (e.g., polycarbonate composition) canoptionally be pumped through a melt filter 60 (e.g., a stainless steelfilter and that has a 2.5 to 50 micrometer) to remove gels and otherimpurities from the polycarbonate composition. Likewise, the melt filter60 can optionally be located before the extruder 40. The polycarbonatecomposition can then be stranded in a die-head and finally pelletizedand packaged. The pellets, so prepared, when cutting the extrudate canbe, for example, one-fourth inch long or less as desired. Such pelletscan be used for subsequent molding, shaping, or forming. Typical nominalthroughput per line ranges from 2 to 15 tons per hour, specifically, 3to 6.6 tons per hour.

The polycarbonate composition can further comprise an additive. Theadditive can include various additives, with the proviso that theadditive(s) are selected so as to not significantly adversely affect adesired property of the thermoplastic composition. The additive can bemixed at a suitable time during the mixing of the components for formingthe composition. The additive can be soluble and/or non-soluble inpolycarbonate. The additive can include flow modifiers, antioxidants,heat stabilizers, light stabilizers, ultraviolet (UV) light stabilizers,UV absorbing additives, plasticizers, lubricants, release agents (suchas mold release agents), antistatic agents, anti-fog agents,antimicrobial agents, colorants, surface effect additives, radiationstabilizers, flame retardants, anti-drip agents (such as TSAN), orcombinations comprising one or more of the foregoing. The additive(s)can be an additive that is not acidic in nature. The total amount ofadditive(s) can be 0.01 to 5 wt %, based on the total weight of thecomposition.

Plasticizers, lubricants, and/or mold release agents can also be used.There is considerable overlap among these types of materials, whichinclude, for example, glycerol tristearate (GTS), glycerol monostearate(GMS), pentaerythritol tetrastearate (PETS), phthalic acid esters suchas dioctyl-4,5-epoxy-hexahydrophthalate;tris-(octoxycarbonylethyl)isocyanurate; tristearin; di- orpolyfunctional aromatic phosphates such as resorcinol tetraphenyldiphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and thebis(diphenyl) phosphate of bisphenol A; poly-alpha-olefins; epoxidizedsoybean oil; silicones, including silicone oils; esters, for example,fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate,stearyl stearate, and the like; combinations of methyl stearate andhydrophilic and hydrophobic nonionic surfactants comprising polyethyleneglycol polymers, polypropylene glycol polymers, poly(ethyleneglycol-co-propylene glycol) copolymers, or a combination comprising atleast one of the foregoing glycol polymers, e.g., methyl stearate andpolyethylene-polypropylene glycol copolymer in a suitable solvent; waxessuch as beeswax, montan wax, paraffin wax, or the like. The mold releaseagent can comprise a polydiorganosiloxane (such as poly(dimethyldiphenyl siloxane)) having a kinematic viscosity of less than or equalto 20 millimeter squared per second (mm²/sec) at 25° C. (specifically,15 mm²/sec to 20 mm²/sec) determined in accordance with ASTM D445, wherethe polydiorganosiloxane can have a phenyl content. The thermoplasticcomposition can be free of stearyl stearate, where the composition cancomprise less than or equal to 0.01 wt %, specifically, 0 to 0.005 wt %stearyl stearate based on the total weight of the composition.

Heat stabilizer additives include organophosphites such as triphenylphosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono- anddi-nonylphenyl)phosphite or the like; phosphonates such asdimethylbenzene phosphonate or the like, phosphates such as trimethylphosphate, or the like, or combinations comprising at least one of theforegoing heat stabilizers. The heat stabilizer can betris(2,4-di-t-butylphenyl) phosphate available as IRGAPHOS™ 168. Heatstabilizers are generally used in amounts of 0.01 to 5 parts by weight,based on 100 parts by weight of polycarbonate.

Light stabilizers and/or ultraviolet light (UV) absorbing additives,also referred to as UV stabilizers, can also be used. Light stabilizeradditives include benzotriazoles such as2-(2-hydroxy-5-methylphenyl)benzotriazole,2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2-hydroxy-4-n-octoxybenzophenone, or the like, or combinations comprising at least one ofthe foregoing light stabilizers.

UV absorbing additives include hydroxybenzophenones;hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates;oxanilides; benzoxazinones; aryl salicylates; monoesters of diphenolssuch as resorcinol monobenzoate;2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB™5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB™ 531);2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol(CYASORB™ 1164); 2,2′-(1,4-phenylene)bis(4H-3, 1-benzoxazin-4-one)(CYASORB™ UV-3638);poly[(6-morphilino-s-triazine-2,4-diyl)[2,2,6,6-tetramethyl-4-piperidyl)imino]-hexamethylene[(2,2,6,6-tetramethyl-4-piperidyl)imino],2-hydroxy-4-octyloxybenzophenone (UVINUL™ 3008),6-tert-butyl-2-(5-chloro-2H-benzotriazole-2-yl)-4-methylphenyl (UVINU™3026), 2,4-di-tert-butyl-6-(5-chloro-2H-benzotriazole-2-yl)-phenol(UVINU™ 3027), 2-(2H-benzotriazole-2-yl)-4,6-di-tert-pentylphenol(UVINUL™ 3028),2-(2H-benzotriazole-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (UVINU™3029),1,3-bis[(2′cyano-3′,3′-diphenylacryloyl)oxy]-2,2-bis-{[(2′-cyano-3′,3′-diphenylacryloyl)oxy]methyl}-propane(UVINU™ 3030), 2-(2H-benzotriazole-2-yl)-4-methylphenol (UVINU™ 3033),2-(2H-benzotriazole-2-yl)-4,6-bis(1-methyl-1-phenyethyl)phenol (UVINU™3034), ethyl-2-cyano-3,3-diphenylacrylate (UVINU™ 3035),(2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (UVINU™ 3039),N,N′-bisformyl-N,N′-bis(2,2,6,6-tetramethyl-4-piperidinyl)hexamethylendiamine(UVINU™ 4050H), bis-(2,2,6,6-tetramethyl-4-pipieridyl)-sebacate (UVINUL™4077H),bis-(1,2,2,6,6-pentamethyl-4-piperdiyl)-sebacate+methyl-(1,2,2,6,6-pentamethyl-4-piperidyl)-sebacate(UVINU™ 4092H)1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL™ 3030);2,2′-(1,4-phenylene) bis(4H-3,1-benzoxazin-4-one);1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane;TINUVIN™ 234; nano-size inorganic materials such as titanium oxide,cerium oxide, and zinc oxide, all with a particle size less than orequal to 100 nanometers; or the like, or combinations comprising atleast one of the foregoing UV absorbers. UV absorbers can be used inamounts of 0.01 to 1 part by weight, based on 100 parts by weight ofpolycarbonate and impact modifier. UV absorbers that can be particularlyuseful with the polycarbonate compositions disclosed herein include2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (e.g.,CYASORB™ 5411 commercially available from Cytec Industries, Inc.,Woodland Park, N.J.) and2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (e.g., CYASORB™UV-3638, commercially available from Cytec Industries, Inc., WoodlandPark, N.J.), and combinations comprising at least one of the foregoing.The UV stabilizers can be present in an amount of 0.01 to 1 wt %,specifically, 0.1 to 0.5 wt %, and more specifically, 0.15 to 0.4 wt %,based upon the total weight of the polycarbonate composition.

A colorant such as pigment and/or dye additives can be present. Usefulpigments can include, for example, inorganic pigments such as metaloxides and mixed metal oxides such as zinc oxide, titanium dioxides,iron oxides, or the like; sulfides such as zinc sulfides, or the like;aluminates; sodium sulfo-silicates sulfates, chromates, or the like;carbon blacks; zinc ferrites; ultramarine blue; organic pigments such asazos, di-azos, quinacridones, perylenes, naphthalene tetracarboxylicacids, flavanthrones, isoindolinones, tetrachloroisoindolinones,anthraquinones, enthrones, dioxazines, phthalocyanines, and azo lakes;Pigment Red 101, Pigment Red 122, Pigment Red 149, Pigment Red 177,Pigment Red 179, Pigment Red 202, Pigment Violet 29, Pigment Blue 15,Pigment Blue 60, Pigment Green 7, Pigment Yellow 119, Pigment Yellow147, Pigment Yellow 150, and Pigment Brown 24; or combinationscomprising at least one of the foregoing pigments.

Dyes are generally organic materials and include coumarin dyes such ascoumarin 460 (blue), coumarin 6 (green), nile red or the like;lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes;polycyclic aromatic hydrocarbon dyes; scintillation dyes such as oxazoleor oxadiazole dyes; aryl- or heteroaryl-substituted poly (C₂₋₈) olefindyes; carbocyanine dyes; indanthrone dyes; phthalocyanine dyes; oxazinedyes; carbostyryl dyes; napthalenetetracarboxylic acid dyes; porphyrindyes; bis(styryl)biphenyl dyes; acridine dyes; anthraquinone dyes;cyanine dyes; methine dyes; arylmethane dyes; azo dyes; indigoid dyes,thioindigoid dyes, diazonium dyes; nitro dyes; quinone imine dyes;aminoketone dyes; tetrazolium dyes; thiazole dyes; perylene dyes,perinone dyes; bis-benzoxazolylthiophene (BBOT); triarylmethane dyes;xanthene dyes; thioxanthene dyes; naphthalimide dyes; lactone dyes;fluorophores such as anti-stokes shift dyes which absorb in the nearinfrared wavelength and emit in the visible wavelength, or the like;luminescent dyes such as 7-amino-4-methylcoumarin;3-(2′-benzothiazolyl)-7-diethylaminocoumarin;2-(4-biphenylyl)-5-(4-t-butylphenyl)-1,3,4-oxadiazole;2,5-bis-(4-biphenylyl)-oxazole; 2,2′-dimethyl-p-quaterphenyl;2,2-dimethyl-p-terphenyl; 3,5, 3″″,5″″-tetra-t-butyl-p-quinquephenyl;2,5-diphenylfuran; 2,5-diphenyloxazole; 4,4′-diphenylstilbene;4-dicyanomethylene-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran;1,1-diethyl-2,2′-carbocyanine iodide;3,3′-diethyl-4,4′,5,5′-dibenzothiatricarbocyanine iodide;7-dimethylamino-1-methyl-4-methoxy-8-azaquinolone-2;7-dimethylamino-4-methylquinolone-2;2-(4-(4-dimethylaminophenyl)-1,3-butadienyl)-3-ethylbenzothiazoliumperchlorate; 3-diethylamino-7-diethyliminophenoxazonium perchlorate;2-(1-naphthyl)-5-phenyloxazole; 2,2′-p-phenylen-bis(5-phenyloxazole);rhodamine 700; rhodamine 800; pyrene, chrysene, rubrene, coronene, orthe like; or combinations comprising at least one of the foregoing dyes.

The polycarbonate compositions are optical grade compositions that canhave one or more the properties shown in Table A.

Unit Method Range Tensile Stress, yld, Type I, 50 mm/min MPa ASTM D 638 20-100 Tensile Strain, yld, Type I, 50 mm/min % ASTM D 638  1-200Tensile Strain, brk, Type I, 50 mm/min % ASTM D 638  50-200 FlexuralStress, yld, 1.3 mm/min, 50 mm span MPa ASTM D 790  70-130 FlexuralModulus, 1.3 mm/min, 50 mm span MPa ASTM D 790  2000-28000 Izod Impact,notched, 23° C. J/m ASTM D 256 400-800 Falling Dart Impact (D 3029), 23°C. J ASTM D 3029 100-200 Instrumented Impact Energy @ peak, 23° C. JASTM D 3763  30-100 Vicat Softening Temp, Rate B/50 ° C. ASTM D 1525140-170 HDT, 0.45 MPa, 6.4 mm, unannealed ° C. ASTM D 648 110-160 HDT,1.82 MPa, 6.4 mm, unannealed ° C. ASTM D 648 110-150 Specific Gravity —ASTM D 792 1.0-1.4 Water Absorption, 24 hours % ASTM D 570   0-0.2 MeltFlow Rate, 300° C./1.2 kg g/10 min ASTM D 1238  2-40In addition, the polycarbonate compositions can be optical-grade.Optical-grade materials are transparent and have a small opticaldistortion. For example, optical grade polycarbonates can have a haze ofless than 1%, less than 0.5%, or less than 0.1%, tested in accordancewith ASTM D1003-00, Procedure B, illuminant C, on a spectrophotometer,at a thickness of 3.2 mm.

Shaped, formed, or molded articles comprising the polycarbonatecompositions are also provided. The polycarbonate compositions can bemolded into useful shaped articles by a variety of means such asinjection molding, extrusion, rotational molding, blow molding, andthermoforming. Formed articles comprising the polycarbonate compositionare particularly useful in optical applications and can be formed intoarticles such as windows, glazings, or media storage devices (such asCDs, DVDs, and BLU-RAY™ discs).

In summary, a process for manufacturing a polycarbonate compositioncomprises melt polymerizing a dihydroxy compound such as bisphenol A anda carbonate compound such as diphenyl carbonate in the presence of acatalyst to form a polycarbonate, and adding 1 to 400 ppm, 1 to 200 ppm,or 1 to 150 ppm of glycerol tristearate to form the polycarbonatecomposition, wherein the polycarbonate composition is unquenched (forexample, at least one of (1) the polycarbonate composition comprises anactive catalyst; (2) the catalyst has not been neutralized; (3) thereactivity between the polycarbonate and the catalyst has not beenreduced; (4) the polycarbonate composition is formed without reducingthe catalyst activity between the polymerization unit and the exit ofthe extruder by the addition of a quenching agent; (5) less than orequal to 50 mol % of an acid relative to any added alpha catalyst hasbeen added; and (6) substantially no quenching agent has been addedduring the manufacture of the polycarbonate); and more particularlyadding a dihydroxy compound such as bisphenol A and a carbonate compoundsuch as diphenyl carbonate and a catalyst to a mixer, oligomerizing thedihydroxy compound and the carbonate compound to form an oligomer, meltpolymerizing the oligomer to form a polymer in a polymerization unit,and adding 1 to 400 ppm, 1 to 200 ppm, or 1 to 150 ppm of glyceroltristearate and any additives to the polymer to form the polycarbonatecomposition, wherein substantially no quenching agent, preferably 0 ppmof a quenching agent, is added during the process, examples of quenchingagents including a boric acid ester, zinc borate, boron phosphate,aluminum stearate, aluminum silicate, zirconium carbonate, zirconiumC₁-C₁₂ alkoxides, zirconium hydroxycarboxylate, gallium phosphide,gallium antimonide, germanium oxide, C₁-C₃₂ organogermanium compound,C₄-C₃₂ tetraorganotin compound, C₄-C₃₂ hexaorganotin compound, Sb₂O₃,antimony oxide, C₁-C₃₂ alkylantimony, bismuth oxide, C₁-C₁₂alkylbismuth, zinc acetate, zinc stearate, C₁-C₃₂ alkoxytitanium, andtitanium oxide, phosphoric acid, phosphorous acid, hypophosphorous acid,pyrophosphoric acid, polyphosphoric acid, boric acid, hydrochloric acid,hydrobromic acid, sulfuric acid, sulfurous acid, adipic acid, azelaicacid, dodecanoic acid, L-ascorbic acid, aspartic acid, benzoic acid,formic acid, acetic acid, citric acid, glutamic acid, salicylic acid,nicotinic acid, fumaric acid, maleic acid, oxalic acid, benzenesulfinicacid, C₁-C₁₂ dialkyl sulfate, alkyl sulfonic ester of the formulaR₁SO₃R₂ wherein R₁ is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉alkylaryl, and R₂ is C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl,sulfonic acid phosphonium salt of the formula (R^(a)SO₃ ⁻)(PR^(b) ₄)⁺wherein R^(a) is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉alkylaryl, and each R^(b) is independently hydrogen, C₁-C₁₂ alkyl orC₆-C₁₈ aryl, sulfonic acid derivative of the formula A¹-(Y¹—SO₃X¹)_(m)wherein A¹ is a C₁-C₄₀ hydrocarbon group having a valence of m, Y¹ is asingle bond or an oxygen atom, X is a secondary or tertiary alkyl groupof the formula —CR¹⁵R¹⁶R¹⁷, a metal cation of one equivalent, anammonium cation or a phosphonium wherein R¹⁵ is a hydrogen atom or analkyl group having 1 to 5 carbon atoms, R¹⁶ is a hydrogen atom, a phenylgroup or an alkyl group having 1 to 5 carbon atoms, and R¹⁷ is the sameas or different from R¹⁵ and has the same definition as R¹⁵, providedthat two of R¹⁵, R¹⁶, and R¹⁷ cannot be hydrogen atoms, and m is aninteger of 1 to 4, provided that when Y is a single bond, all of X in anamount of m cannot be metal cations of one equivalent, a compound of theformula ⁺X²-A²-Y¹—SO₃ ⁻ wherein A² is a divalent hydrocarbon group, ⁺X²is a secondary, tertiary or quaternary ammonium cation or a secondary,tertiary or quaternary phosphonium cation, and Y is a single bond or anoxygen atom, a compound of the formula A³-(⁺X³)_(n′)(R—Y¹—SO₃ ⁻)_(n)wherein A³ is a C₁-C₄₀ hydrocarbon group having a valence of n, ⁺X³ is asecondary, tertiary or quaternary ammonium cation or a secondary,tertiary or quaternary phosphonium cation, R is a monovalent C₁-C₄₀hydrocarbon group, n is an integer of 2 to 4, and Y¹ is a single bond oran oxygen atom, a compound of the formula A⁵-Ad¹-A⁴-(Ad²-A⁵)_(l) whereinA⁵ is a monovalent or divalent C₁-C₄₀ hydrocarbon group, A⁴ is adivalent C₁-C₄₀ hydrocarbon group, each of Ad and Ad² is independentlyan acid anhydride group selected from —SO₂—O—SO₂—, —SO₂—O—CO— and—CO—O—SO₂—, and l is 0 or 1, provided that when t is O, -(Ad²-A⁵)_(l) isa hydrogen atom or a bond between A⁴ and A⁵, in which A⁵ is a divalenthydrocarbon group or a single bond, aminosulfonic esters having theformula R_(a)R_(b)N-A-SO₃R_(c), wherein R_(a) and R_(b) are eachindependently hydrogen, C₁-C₁₂ alkyl, C₆-C₂₂ aryl, C₇-C₁₉ alkylaryl orR_(a) and R_(b), either singly or in combination, form an aromatic ornon-aromatic heterocyclic compound with N, R_(c) is hydrogen, and A isC₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₁₇-C₁₉ alkylaryl, ammonium sulfonicesters of the formula R_(a)R_(b)R_(c)N⁺-A-SO₃ ⁻, wherein R_(a), R_(b),are each independently hydrogen, C₁-C₁₂ alkyl, C₁-C₁₂ aryl, C₇-C₁₉alkylaryl, or R_(a) and R_(b), either singly or in combination, form anaromatic or non-aromatic heterocyclic compound with N, R_(c) is ahydrogen, and A is C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl,sulfonated polystyrene, methyl acrylate-sulfonated styrene copolymer, ora combination comprising at least one of the foregoing quenching agents.

Optionally, in any of the foregoing methods an additive can be added,wherein the additive comprises a colorant, a heat stabilizer, anantioxidant, a UV absorbing additive, an antistatic agent, a flowmodifier, an anti-fog additive, an antimicrobial agent, a flameretardant, or a combination comprising one or more of the foregoing,preferably wherein the additive is not acidic. Any of the foregoingmethods can further optionally comprise extruding, filtering, andpelletizing the polycarbonate composition to form polycarbonate pellets,wherein the glycerol tristearate can optionally be added to the extruderduring extruding the polycarbonate composition.

Unquenched polycarbonate compositions formed by any of the foregoingmethods can have a haze of less than 1%, less than 0.5%, or less than0.1%, tested in accordance with ASTM D1003-00, Procedure B, illuminantC, on a spectrophotometer, at a thickness of 3.2 mm, and can be used tomanufacture an article, for example, by molding. Exemplary articlesinclude a DVD, a CD, or a Blu-ray disc.

The following examples are provided to illustrate the method ofpreparing the polycarbonate. The examples are merely illustrative andare not intended to limit methods made in accordance with the disclosureto the materials, conditions, or process parameters set forth therein.

EXAMPLES

Experiments were run in a continuous melt polycarbonate plant asillustrated in FIG. 1. In the experiments, 39.8 kilograms per hour(kg/h) BPA and 37.3 kg/h of DPC and an endcapping agent were fed into acontinuously stirred pre-mixer 10, where pre-mixer 10 was operated atatmospheric pressure, and a temperature of 160 to 180° C. A 3.2 wt %aqueous solution of tetrabutyl phosphonium acetate was also added to thepre-mixer at a rate of 75 to 95 milliliters per hour (mL/h).

The outlet stream of the pre-mixer 10 was then pumped to a continuouslystirred first oligomerization vessel 20, which was operated at 240 to270° C. and 150 to 200 mbara vacuum. A vapor phase containing phenol andunreacted monomers BPA and DPC was removed from the oligomerizationvessel 20 and was continuously distilled in a scrubber 50 where thereflux ratio was adjusted so that the column head temperature was 125 to130° C. to yield high purity phenol. Unreacted BPA and DPC were recycledback into the oligomerization vessel 20. Additional DPC was added to theoligomerization vessel 20 at a rate of 0.9 to 1.35 kg/h in order tocompensate for DPC losses in the phenol overhead streams of theforthcoming reactors. An aqueous stream of 50 ppm NaOH was also added inthe oligomerization vessel 20 at a flowrate of 0.255 to 0.8 millilitersper minute (mL/min).

The outlet stream of the oligomerization vessel 20 was then pumped to asecond oligomerization vessel 21, where the oligomerization vessel 21was operated at 270 to 285° C. and 35-40 mbara vacuum. Due to the higherviscosity of the outlet stream of oligomerization vessel 21, a gear pump(not shown) was used to convey the outlet stream to the firstpolymerization vessel 30. Polymerization vessel 30 was operated at 285to 302° C. and 2.5 to 3.0 mbara vacuum. The polymer stream exitingpolymerization vessel 30 was then pumped to a second polymerizationvessel 31, that was operated at a deeper vacuum of 1.0 to 1.5 mbara and285 to 305° C. Phenol was removed from oligomerization vessel 21 andpolymerization vessels 30 and 31.

The resultant polycarbonate had a weight average molecular weight of36,500 Daltons based on polystyrene standards, a minimum endcap ratio of80%, and a branching level of 1,000 ppm. It is noted that a quenchingagent was not added to the polycarbonate and that any remaining catalystwas still active. The polymerized polycarbonate was introduced to atwin-screw extruder 40, where additives as described in Table 1 wereadded.

TABLE 1 Additive 1 2 3 4 5 6 7 8 9 GMS (ppm) 400 0 0 0 400 0 400 0 0PETS (ppm) 220 100 220 400 0 0 125 0 0 Irgafos 168 (ppm) 220 220 220 220220 220 220 220 220 GTS (ppm) 0 0 0 0 0 400 0 190 120The resultant mixture was then filtered in filter 60 and pelletized. 70total discs were made from each of Examples 1-9 using the conditions asdescribed in Table 2, where 10 discs were made per condition.

TABLE 2 1 2 3 4 5 6 7 Barrel T (° C.) 335 360 380 360 360 335 335 Mold T(° C.) 38/44 38/44 38/44 38/44 48/54 48/54 38/44

A “cloud level” was assigned to each disc. No clouds received a score of1, low or hardly visible clouds received a score of 2, some cloudsreceived a score of 3, some clouds received a score of 4, severe cloudsreceived a score of 5, and very severe clouds received a score of 6. Thecloud level of each of the 10 discs for each testing condition of eachcomposition was averaged together and the 7 averaged scores for eachcomposition were added together to obtain a final cloud level for amaximum cloud level of 42 and a minimum cloud level of 7. The resultingmaximum cloud levels are shown in FIG. 2, where Example 10 is anunquenched, commercially available sample of an optical quality gradefor media storage polycarbonate, SABIC™ PC4800, commercially availablefrom SABIC's Innovative Plastics business, and Example 11 is a quenched,commercially available sample of an optical quality grade for mediastorage polycarbonate, LEXAN™ OQ 1028, commercially available fromSABIC's Innovative Plastics business.

FIG. 2 shows that unquenched Examples 8 and 9 that comprised less than400 ppm of GTS resulted in cloud levels of less than or equal to thequenched optical quality grade polycarbonate of Example 11. FIG. 2 alsoshows that Example 2 that had 100 ppm of PETS resulted in a relativelylow cloud level in unquenched polycarbonate. However, as noted above,use of PETS can also reduce other optical qualities of discs, such ascolor, and therefore is not as desirable as GTS in an amount of lessthan 400 ppm, and even more preferably less than 200 ppm. It is alsonotable that as shown in Example 9 vs. Example 11, amounts of GTS lessthan 150 ppm give better results than the unquenched composition. Inaddition, Examples 6, 8, and 9 can have a haze of less than 1%, lessthan 0.5%, or less than 0.1%, tested in accordance with ASTM D1003-00,Procedure B, illuminant C, on a spectrophotometer, at a thickness of 3.2mm.

Set forth below are some embodiments of the present method ofmanufacturing a polycarbonate composition.

Embodiment 1

A process for manufacturing a polycarbonate composition comprising: meltpolymerizing a dihydroxy compound and a carbonate compound in thepresence of a catalyst to form a polycarbonate; and adding 1 to 400 ppmof glycerol tristearate to form the polycarbonate composition, whereinthe polycarbonate composition is unquenched, wherein the polycarbonatehas a weight average molecular weight of 8,000 to 19,000 Daltons asdetermined by gel permeation chromatography and based on polycarbonatestandards.

Embodiment 2

The process of Embodiment 1, comprising adding 1 to 200 ppm of theglycerol tristearate.

Embodiment 3

The process of Embodiment 2, comprising adding 1 to 150 ppm of theglycerol tristearate.

Embodiment 4

The process of any one of Embodiments 1 to 3, wherein one or more of thefollowing conditions apply: (1) the polycarbonate composition comprisesan active catalyst; (2) the catalyst has not been neutralized; (3) thereactivity between the polycarbonate and the catalyst has not beenreduced; (4) the polycarbonate composition is formed without reducingthe catalyst activity between the polymerization unit and the exit ofthe extruder by the addition of a quenching agent; (5) less than orequal to 50 mol % of an acid relative to any added alpha catalyst hasbeen added; and (6) substantially no quenching agent has been addedduring the manufacture of the polycarbonate.

Embodiment 5

A process for manufacturing a polycarbonate composition comprising:adding a dihydroxy compound, a carbonate compound, and a catalyst to amixer, oligomerizing the dihydroxy compound and the carbonate compoundto form an oligomer, melt polymerizing the oligomer to form a polymer ina polymerization unit, adding 1 to 400 ppm of glycerol tristearate andany additives to the polymer to form the polycarbonate composition;wherein substantially no quenching agent is added during the process,wherein the polycarbonate has a weight average molecular weight of 8,000to 19,000 Daltons as determined by gel permeation chromatography andbased on polycarbonate standards.

Embodiment 6

The process of any one of Embodiments 1 to 5, wherein 0 ppm of anyquenching agent is added during the process.

Embodiment 7

The process of Embodiment 6, wherein the quenching agent is a boric acidester, zinc borate, boron phosphate, aluminum stearate, aluminumsilicate, zirconium carbonate, zirconium C₁-C₁₂ alkoxides, zirconiumhydroxycarboxylate, gallium phosphide, gallium antimonide, germaniumoxide, C₁-C₃₂ organogermanium compound, C₄-C₃₂ tetraorganotin compound,C₄-C₃₂ hexaorganotin compound, Sb₂O₃, antimony oxide, C₁-C₃₂alkylantimony, bismuth oxide, C₁-C₁₂ alkylbismuth, zinc acetate, zincstearate, C₁-C₃₂ alkoxytitanium, and titanium oxide, phosphoric acid,phosphorous acid, hypophosphorous acid, pyrophosphoric acid,polyphosphoric acid, boric acid, hydrochloric acid, hydrobromic acid,sulfuric acid, sulfurous acid, adipic acid, azelaic acid, dodecanoicacid, L-ascorbic acid, aspartic acid, benzoic acid, formic acid, aceticacid, citric acid, glutamic acid, salicylic acid, nicotinic acid,fumaric acid, maleic acid, oxalic acid, benzenesulfinic acid, C₁-C₁₂dialkyl sulfate, alkyl sulfonic ester of the formula R₁SO₃R₂ wherein R,is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, and R₂ isC₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, sulfonic acidphosphonium salt of the formula (R^(a)SO₃ ⁻)(PR^(b) ₄)⁺ wherein R^(a) ishydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, and each R^(b)is independently hydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl, sulfonic acidderivative of the formula A¹-(Y¹—SO₃X¹)_(m) wherein A is a C₁-C₄₀hydrocarbon group having a valence of m, Y is a single bond or an oxygenatom, X is a secondary or tertiary alkyl group of the formula—CR^(1S)R¹⁶R¹⁷, a metal cation of one equivalent, an ammonium cation ora phosphonium wherein R¹⁵ is a hydrogen atom or an alkyl group having 1to 5 carbon atoms, R¹⁶ is a hydrogen atom, a phenyl group or an alkylgroup having 1 to 5 carbon atoms, and R¹⁷ is the same as or differentfrom R¹⁵ and has the same definition as R¹⁵, provided that two of R¹⁵,R¹⁶, and R¹⁷ cannot be hydrogen atoms, and m is an integer of 1 to 4,provided that when Y is a single bond, all of X in an amount of m cannotbe metal cations of one equivalent, a compound of the formula⁺X²-A²-Y¹—SO₃ ⁻ wherein A² is a divalent hydrocarbon group, ⁺X² is asecondary, tertiary or quaternary ammonium cation or a secondary,tertiary or quaternary phosphonium cation, and Y¹ is a single bond or anoxygen atom, a compound of the formula A³-(⁺X³)_(n′)(R—Y¹—SO₃ ⁻)_(n)wherein A³ is a C₁-C₄₀ hydrocarbon group having a valence of n, ⁺X³ is asecondary, tertiary or quaternary ammonium cation or a secondary,tertiary or quaternary phosphonium cation, R is a monovalent C₁-C₄₀hydrocarbon group, n is an integer of 2 to 4, and Y¹ is a single bond oran oxygen atom, a compound of the formula A⁵-Ad¹-A⁴-(Ad²-A⁵)_(l) whereinA⁵ is a monovalent or divalent C₁-C₄₀ hydrocarbon group, A⁴ is adivalent C₁-C₄₀ hydrocarbon group, each of Ad¹ and Ad² is independentlyan acid anhydride group selected from —SO₂—O—SO₂—, —SO₂—O—CO— and—CO—O—SO₂—, and l is 0 or 1, provided that when l is O, -(Ad²-A⁵)_(l) isa hydrogen atom or a bond between A⁴ and A⁵, in which A⁵ is a divalenthydrocarbon group or a single bond, aminosulfonic esters having theformula R_(a)R_(b)N-A-SO₃R_(c), wherein R and R_(b) are eachindependently hydrogen, C₁-C₁₂ alkyl, C₆-C₂₂ aryl, C₇-C₁₉ alkylaryl orR_(a) and R_(b), either singly or in combination, form an aromatic ornon-aromatic heterocyclic compound with N, R_(c) is hydrogen, and A isC₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₁₇-C₁₉ alkylaryl, ammonium sulfonicesters of the formula R_(a)R_(b)R_(c)N⁺-A-SO₃ ⁻, wherein R_(a), R_(b),are each independently hydrogen, C₁-C₁₂ alkyl, C₁-C₁₂ aryl, C₇-C₁₉alkylaryl, or R_(a), and R_(b), either singly or in combination, form anaromatic or non-aromatic heterocyclic compound with N, R_(c) is ahydrogen, and A is C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl,sulfonated polystyrene, methyl acrylate-sulfonated styrene copolymer, ora combination comprising at least one of the foregoing quenching agents.

Embodiment 8

The process of any one of Embodiments 1 to 7, further comprising addingan additive, wherein the additive comprises a colorant, a heatstabilizer, an antioxidant, a UV absorbing additive, an antistaticagent, a flow modifier, an anti-fog additive, an antimicrobial agent, aflame retardant, or a combination comprising one or more of theforegoing.

Embodiment 9

The process of Embodiment 8, wherein the additive is not acidic.

Embodiment 10

The process of any one of Embodiments 1 to 9, wherein the molecularweight is 13,000 to 18,500 Daltons.

Embodiment 11

The process of any one of Embodiments 1 to 10, wherein the molecularweight is 13,000 to 18,000 Daltons.

Embodiment 12

The process of any one of Embodiments 1 to 11, wherein the polycarbonatehas terminal hydroxyl groups in an amount of less than or equal to 20mol % based on the molar total of all terminal groups of thepolycarbonate.

Embodiment 13

The process of any one of Embodiments 1 to 12, wherein the polycarbonatehas a melt flow of less than or equal to 40 grams per 10 minutes (g/10min) as determined by ASTM D1238 at 250° C., 1.5 kg.

Embodiment 14

The process of Embodiment 13, wherein the melt flow is less than orequal to 10 g/10 min.

Embodiment 15

The process of Embodiment 14, wherein the melt flow is 4 to 10 g/10 min.

Embodiment 16

The process of any one of Embodiments 1 to 15, wherein a branchingstructure is present in an amount of less than or equal to 2,000 ppm.

Embodiment 17

The process of Embodiments 16, wherein the branching structure ispresent in an amount of less than or equal to 500 ppm.

Embodiment 18

The process of any one of Embodiments 1 to 17, wherein the polycarbonatecomposition is free of stearyl stearate.

Embodiment 19

The process of any one of Embodiments 1 to 18, further comprisingextruding, filtering, and pelletizing the polycarbonate composition toform polycarbonate pellets.

Embodiment 20

The process of Embodiment 19, wherein the glycerol tristearate is addedto the extruder during extruding the polycarbonate composition.

Embodiment 21

An unquenched polycarbonate composition formed by any one of Embodiments1 to 20.

Embodiment 22

The unquenched polycarbonate composition of Embodiment 21, having a hazeof less than 1%, tested in accordance with ASTM D1003-00, Procedure B,illuminant C, on a spectrophotometer, at a thickness of 3.2 mm.

Embodiment 23

The unquenched polycarbonate composition of any one of Embodiments 21 to22, having a light transparency of greater than 90% as determined using3.2 mm thick samples using ASTM D1003-00, Procedure B using CIE standardilluminant C, with unidirectional viewing.

Embodiment 24

A process of forming an article, comprising molding the polycarbonatepellets of any of Embodiments 19 and 20 into an article.

Embodiment 25

The process of Embodiment 24, wherein the article is a DVD, a CD, or aBlu-ray disc.

All ranges disclosed herein are inclusive of the endpoints, and theendpoints are independently combinable with each other (e.g., ranges of“up to 25 wt %, or, more specifically, 5 to 20 wt %”, is inclusive ofthe endpoints and all intermediate values of the ranges of “5 to 25 wt%,” etc.). “Combination” is inclusive of blends, mixtures, alloys,reaction products, and the like. Furthermore, the terms “first,”“second,” and the like, herein do not denote any order, quantity, orimportance, but rather are used to denote one element from another. Theterms “a” and “an” and “the” herein do not denote a limitation ofquantity, and are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The suffix “(s)” as used herein is intended to include both thesingular and the plural of the term that it modifies, thereby includingone or more of that term (e.g., the film(s) includes one or more films).Reference throughout the specification to “one embodiment,” “anotherembodiment,” “an embodiment,” and so forth, means that a particularelement (e.g., feature, structure, and/or characteristic) described inconnection with the embodiment is included in at least one embodimentdescribed herein, and may or may not be present in other embodiments. Inaddition, it is to be understood that the described elements can becombined in any suitable manner in the various embodiments.

While the disclosure has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes can be made and equivalents can be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications can be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

We claim:
 1. A process for manufacturing a polycarbonate compositioncomprising: melt polymerizing a dihydroxy compound and a carbonatecompound in the presence of a catalyst comprising a source of alkali oralkaline earth ions to form a polycarbonate; and adding 1 to less than400 ppm of glycerol tristearate to form the polycarbonate composition,wherein the polycarbonate composition is unquenched, wherein thepolycarbonate has a weight average molecular weight of 8,000 to 19,000Daltons as determined by gel permeation chromatography and based onpolycarbonate standards.
 2. The process of claim 1, wherein themolecular weight is 13,000 to 18,500 Daltons.
 3. The process of claim 2,comprising adding 1 to 200 ppm of the glycerol tristearate.
 4. Theprocess of claim 1, wherein one or more of the following conditionsapply: (1) the polycarbonate composition comprises an active catalyst;(2) the catalyst has not been neutralized; (3) the reactivity betweenthe polycarbonate and the catalyst has not been reduced; (4) thepolycarbonate composition is formed without reducing the catalystactivity between the polymerization unit and the exit of the extruder bythe addition of a quenching agent; (5) less than or equal to 50 mol % ofan acid relative to any added alpha catalyst has been added; and (6)substantially no quenching agent has been added during the manufactureof the polycarbonate.
 5. The process of claim 1, wherein 0 ppm of anyquenching agent is added during the process.
 6. The process of claim 5,wherein the quenching agent is a boric acid ester, zinc borate, boronphosphate, aluminum stearate, aluminum silicate, zirconium carbonate,zirconium C₁-C₁₂ alkoxides, zirconium hydroxycarboxylate, galliumphosphide, gallium antimonide, germanium oxide, C₁-C₃₂ organogermaniumcompound, C₄-C₃₂ tetraorganotin compound, C₄-C₃₂ hexaorganotin compound,Sb₂O₃, antimony oxide, C₁-C₃₂ alkylantimony, bismuth oxide, C₁-C₁₂alkylbismuth, zinc acetate, zinc stearate, C₁-C₃₂ alkoxytitanium, andtitanium oxide, phosphoric acid, phosphorous acid, hypophosphorous acid,pyrophosphoric acid, polyphosphoric acid, boric acid, hydrochloric acid,hydrobromic acid, sulfuric acid, sulfurous acid, adipic acid, azelaicacid, dodecanoic acid, L-ascorbic acid, aspartic acid, benzoic acid,formic acid, acetic acid, citric acid, glutamic acid, salicylic acid,nicotinic acid, fumaric acid, maleic acid, oxalic acid, benzenesulfinicacid, C₁-C₁₂ dialkyl sulfate, alkyl sulfonic ester of the formulaR₁SO₃R₂ wherein R₁ is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉alkylaryl, and R₂ is C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl,sulfonic acid phosphonium salt of the formula (R^(a)SO₃ ⁻)(PR^(b) ₄)⁺wherein R₁ is hydrogen, C₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl,and each R^(b) is independently hydrogen, C₁-C₁₂ alkyl or C₆-C₁₈ aryl,sulfonic acid derivative of the formula A¹-(Y¹—SO₃X¹)_(m) wherein A¹ isa C₁-C₄ hydrocarbon group having a valence of m, Y¹ is a single bond oran oxygen atom, X¹ is a secondary or tertiary alkyl group of the formula—CR¹⁵R¹⁶R¹⁷, a metal cation of one equivalent, an ammonium cation or aphosphonium wherein R¹⁵ is a hydrogen atom or an alkyl group having 1 to5 carbon atoms, R¹⁶ is a hydrogen atom, a phenyl group or an alkyl grouphaving 1 to 5 carbon atoms, and R¹⁷ is the same as or different from R¹⁵and has the same definition as R¹⁵, provided that two of R¹⁵, R¹⁶, andR¹⁷ cannot be hydrogen atoms, and m is an integer of 1 to 4, providedthat when Y¹ is a single bond, all of X¹ in an amount of m cannot bemetal cations of one equivalent, a compound of the formula X²-A²-Y¹—SO₃⁻ wherein A² is a divalent hydrocarbon group, ⁺X² is a secondary,tertiary or quaternary ammonium cation or a secondary, tertiary orquaternary phosphonium cation, and Y¹ is a single bond or an oxygenatom, a compound of the formula A³-(⁺X³)_(n′)(R—Y¹—SO₃ ⁻)_(n) wherein A³is a C₁-C₄₀ hydrocarbon group having a valence of n, ⁺X³ is a secondary,tertiary or quaternary ammonium cation or a secondary, tertiary orquaternary phosphonium cation, R is a monovalent C₁-C₄₀ hydrocarbongroup, n is an integer of 2 to 4, and Y¹ is a single bond or an oxygenatom, a compound of the formula A⁵-Ad¹-A⁴-(Ad²-A⁵)_(t) wherein A⁵ is amonovalent or divalent C₁-C₄₀ hydrocarbon group, A⁴ is a divalent C₁-C₄₀hydrocarbon group, each of Ad¹ and Ad² is independently an acidanhydride group selected from —SO₂—O—SO₂—, —SO₂—O—CO— and —CO—O—SO₂—,and l is 0 or 1, provided that when C is O, -(Ad²-A⁵)_(t) is a hydrogenatom or a bond between A⁴ and A⁵, in which A⁵ is a divalent hydrocarbongroup or a single bond, aminosulfonic esters having the formulaR_(a)R_(b)N-A-SO₃R_(c), wherein R_(a) and R_(b) are each independentlyhydrogen, C₁-C₁₂ alkyl, C₆-C₂₂ aryl, C₇-C₁₉ alkylaryl or R_(a) andR_(b), either singly or in combination, form an aromatic or non-aromaticheterocyclic compound with N, R_(c) is hydrogen, and A is C₁-C₁₂ alkyl,C₆-C₁₈ aryl, or C₁₇-C₁₉ alkylaryl, ammonium sulfonic esters of theformula R_(a)R_(b)R_(c)N⁺-A-SO₃ ⁻, wherein R_(a) and R_(b) are eachindependently hydrogen, C₁-C₁₂ alkyl, C₁-C₁₂ aryl, C₇-C₁₉ alkylaryl, orR_(a) and R_(b), either singly or in combination, form an aromatic ornon-aromatic heterocyclic compound with N, R_(c) is a hydrogen, and A isC₁-C₁₂ alkyl, C₆-C₁₈ aryl, or C₇-C₁₉ alkylaryl, sulfonated polystyrene,methyl acrylate-sulfonated styrene copolymer, or a combinationcomprising at least one of the foregoing quenching agents.
 7. Theprocess of claim 1, further comprising adding an additive, wherein theadditive comprises a colorant, a heat stabilizer, an antioxidant, a UVabsorbing additive, an antistatic agent, a flow modifier, an anti-fogadditive, an antimicrobial agent, a flame retardant, or a combinationcomprising one or more of the foregoing.
 8. The process of claim 7,wherein the additive is not acidic.
 9. The process of claim 1, furthercomprising extruding, filtering, and pelletizing the polycarbonatecomposition to form polycarbonate pellets.
 10. A process of forming anarticle, comprising molding the polycarbonate pellets of claim 9 into anarticle.
 11. The process of claim 10, wherein the article is a DVD, aCD, or a Blu-ray disc.
 12. An unquenched polycarbonate compositionformed by the process of claim
 1. 13. The unquenched polycarbonatecomposition of claim 12, having a haze of less than 1%, tested inaccordance with ASTM D1003-00, Procedure B, illuminant C, on aspectrophotometer, at a thickness of 3.2 mm.
 14. A process formanufacturing a polycarbonate composition comprising: melt polymerizinga dihydroxy compound and a carbonate compound in the presence of acatalyst comprising a source of alkali or alkaline earth ions to form apolycarbonate; and adding 1 to 350 ppm of the glycerol tristearate toform the polycarbonate composition, wherein the polycarbonatecomposition is unquenched such that 0 ppm of any quenching agent isadded during the process, wherein the polycarbonate has a weight averagemolecular weight of 8,000 to 19,000 Daltons as determined by gelpermeation chromatography and based on polycarbonate standards.
 15. Aprocess for manufacturing a polycarbonate composition comprising: addinga dihydroxy compound, a carbonate compound, and a catalyst to a mixer;oligomerizing the dihydroxy compound and the carbonate compound to forman oligomer; melt polymerizing the oligomer to form a polymer in apolymerization unit, adding 1 to 400 ppm of glycerol tristearate and anyadditives to the polymer to form the polycarbonate composition; whereinsubstantially no quenching agent is added during the process, whereinthe polycarbonate has a weight average molecular weight of 8,000 to19,000 Daltons as determined by gel permeation chromatography and basedon polycarbonate standards.
 16. The process of claim 15, wherein one ormore of the following conditions apply: (1) the polycarbonatecomposition comprises an active catalyst; (2) the catalyst has not beenneutralized; (3) the reactivity between the polycarbonate and thecatalyst has not been reduced; (4) the polycarbonate composition isformed without reducing the catalyst activity between the polymerizationunit and the exit of the extruder by the addition of a quenching agent;(5) less than or equal to 50 mol % of an acid relative to any addedalpha catalyst has been added; and (6) substantially no quenching agenthas been added during the manufacture of the polycarbonate.
 17. Theprocess of claim 15, comprising adding 1 to 350 ppm of the glyceroltristearate.
 18. The process of claim 15, wherein 0 ppm of any quenchingagent is added during the process.
 19. The process of claim 15, whereinthe molecular weight is 13,000 to 18,500 Daltons.